Spicer S110, S130 User Manual
Spicer
®
Single Drive Axles
Service Manual
AXSM0055
April 2011
S110 Series
S130 Series
General Information
General Information
The description and specifications contained in this service
publication are current at the time of printing.
Dana reserves the right to discontinue or to modify its
models and/or procedures and to change specifications
at any time without notice.
Important Notice
This symbol is used throughout this
manual to call attention to procedures
where carelessness or failure to follow
specific instructions may result in
personal injury and/or component
damage.
Departure from the instructions, choice
of tools, materials and recommended
parts mentioned in this publication
may jeopardize the personal safety
of the service technician or vehicle
operator.
Any reference to brand name in this publication is made simply as an example of the types of tools and materials recommended for use and should not be considered an
endorsement. Equivalents, if available, may be used.
WARNING: Failure to follow indicated
procedures creates a high risk of personal
njury to the servicing technician.
i
CAUTION: Failure to follow indicated
procedures may cause component
damage or malfunction.
IMPORTANT: Highly recommended
procedures for proper service of this unit.
NOTE: Additional service information not
cover ed in the service procedures.
General Information
TIP: Helpful removal and installation
procedures to aid in the service of this unit.
Refer to the OEM vehicle specifications
OEM
Always use genuine Spicer replacement parts.
i
Table of Contents
General Information .............................................i
Important Notice.......................................................... i
Introduction ........................................................1
Model Listing.............................................................. 1
Model Information ...................................................... 1
Model Identification .................................................... 2
Part Identification........................................................ 2
Ring Gear and Pinion ..........................................3
Inspection ...........................................................4
Failure Analysis........................................................... 4
How to Diagnose a Failure........................................... 4
.........................Prepare the Parts for Inspection 5
Find the Cause of the Failure....................................... 5
Correct the Cause of the Problem............................... 5
Inspection................................................................... 6
Inspect Axle Housing .................................................. 6
Inspect Components................................................... 7
Inspect Primary Gearing ............................................. 7
Differential Carrier Assembly ..............................8
S110 Carrier Assembly .......................................9
S130 Carrier Assembly .....................................11
Remove Differential Carrier ...............................12
Standard Differentials................................................ 12
Install Differential Carrier ..................................13
Remove Wheel Differential ................................14
Pinion - Parts Exploded View ............................15
Pinion Removal .................................................16
Drive Pinion ......................................................17
Rear Axle Pinion Assembly - Parts Exploded View.... 17
Pinion Installation .............................................18
Final Buildup............................................................. 18
Wheel Differential Assembly - Parts Exploded ..20
Disassemble, Overhaul, and Assemble Wheel
Differential - S110 .............................................21
Disassemble Wheel Differential ................................. 21
Disassemble, Overhaul, and Assemble Wheel Differ-
ential - S130 .....................................................26
Disassemble Wheel Differential ................................. 26
Measure and Adjust Carrier Assembly ..............32
Adjust Backlash and Preload ..................................... 32
Change Backlash Setting........................................... 33
Measure Ring Gear Runout ....................................... 33
Adjust Ring and Pinion Tooth Contact Pattern ..34
Install Axle Housing Breather ............................36
Wheel End Seal - Parts Exploded View .............37
Remove and Overhaul Wheel End Seal .............38
Adjust Wheel Bearing ........................................39
Wheel End .........................................................41
Verify Wheel End-play Procedure .............................. 41
Adjust End-play with Tire and Wheel Assembly......... 41
Adjust End-play with Wheel Hub................................ 41
Readjust Wheel End-play Procedure.......................... 41
Lubricate Wheel End .........................................42
Lubrication ........................................................ 44
Approved Lubricants ................................................. 44
Recommendations for Viscosity/Ambient Temp........ 44
Lube Change Intervals............................................... 45
Change Lube .....................................................46
Drain .......................................................................... 46
Fill.............................................................................. 46
Proper Vehicle Towing ......................................47
With Truetrac Limited Slip Differential....................... 47
Torque Flow ......................................................48
Torque Chart .....................................................49
Introduction
Introduction
Dana Commercial Vehicle Division, presents this publication to aid in maintenance and overhaul of Spicer single drive axles.
Instructions contained cover the models listed. Their design is common, with differences in load capacity. Capacity variations
are achieved by combining basic differential carrier assemblies with different axle housings, axle shafts and wheel equipment.
Model Listing
Rear Axle Load Capacity
S10-110 10,000
S12-110 12,000
S14-110 14,000
S16-130 16,000
Model Information
S - S i ngle Rear A xle
G A W Rating x 1 0 0 0 lbs.
Gear Typ e
1 - S tan dard S i n gle Redu ct io n
2 - Dual R a n g e
3 - P lanet ary Dou b le Redu ctio n
4 - Con trolled T r action Diff erent ial
5 - H elical R e d uct i on
Introduction
S 14 - 1 1 0 L
O p t i o n s
B - B u s Specif i c
D - D iff erent ial L ock
H - H eavy Wall
I - I n t e g ral B rake
L - Limit e d-Slip
R - R e t ard e r/Par king Brake Read y
W - Wid e - t r ack
F - Roll Over
D esign L evel
H ead A ssem bly S e r ies
1
Model Identification
Drive Axle
Data plate is located on
the axle centerline
Introduction
3
2
4
CUST. PART NO.
SPEC. SERIAL NO.
MODEL PART NO. RATIO
MADE IN:
Spicer
5
®
6
Rear Axle (Front View)
1 - Country of origin
2 - Axle model identification
3 - Specification number assigned to the axle built by Spicer.
Identifies all component parts of the axle including special
special OEM requirements such as yokes or flanges.
4 - OEM part number assigned to the axle build
5 - Carrier assembly serial number assigned by the
manufacturing plant
6 - Axle gear ratio
7 - Carrier assembly production or service part number
Part Identification
Axle Housing Axle Shaft
®
LBS.
Spicer
PT. NO.
HSG. CAP.
. I.D. NO.
ADE IN
HSG
HOUSING M
1
1
7
2
1 - ID Tag 2 - Axle shaft part number
2
Introduction
Ring Gear and Pinion
Note: Ring gear and drive pinion are matched parts and must be replaced in sets.
127381
1
3
L7038
G
17
OF
4
6
SPICER
7
8
41-8
NL2
5
2
8
8-41
127428
127
6
0H
17
G
Introduction
127
7
SPICER
3
1
1 - Part number
2 - Number of ring gear teeth
3 - Manufacturing numbers
6-39
JD77
85405
8
6
4
4 - Matching gear set number
5 - Number of pinion teeth
7 - Indicates genuine Spicer parts
8 - Heat Code
6 - Date code
3
Inspection
General Information
Failure Analysis
Failure analysis is the process of determining the original
cause of a component failure in order to keep it from happening again. Too often, when a failed component is
without determining its cause, there will be a recurring failure.
If a carrier housing is opened, revealing a ring gear with a broken tooth, it is not enough to settle on the broken tooth as the
cause of the carrier failure.
examined. For a thorough understanding of the failure and
possible insight into related problems, the technician needs to
observe the overall condition of the vehicle.
No one benefits when a failed component goes on the junk
pile with th
customer than a repeat failure. Systematically analyzing a failure to prevent a repeat occurrence assures quality
avoiding unnecessary downtime and further expense to the
customer.
The true cause of a failure can be better determined by knowing what to look for, determining how a piece of the equipment was running and learning about previous problems. In
the
been installed. The more successful shops prevent repeat
equipment failures by developing good failure analysis practices. Knowing how to diagnose the cause of a premature failure is one of the prerequisites of
technician.
e cause unknown. Nothing is more disturbing to a
case of a rebuilt rear axle, mismatched gears may have
Other parts of the carrier must be
a good heavy-equipment
replaced
service by
How to Diagnose a Failure
The following five steps are an effective approach to good failure diagnostics.
1. Document the problem.
2. Make a preliminary investigation.
3. Prepare the parts for inspection.
4. Find the cause of the failure.
5. Correct the cause of the problem.
4. Ask: In what type of service is the truck being used?
5. Ask: Has this particular failure
6. Ask: How was the truck working
You need to be a good listener. Sometimes, insignificant or unrelated symptoms can point to the cause of the failure:
7. Ask: Was the vehicle operating at normal temperatures?
8. Ask: Were the gauges showing normal ranges of
operation?
9. Ask: Was there any unusual noise or vibration?
After listening, review the previous repair and maintenance
rds. If there is more than one driver, talk to all of them
reco
and compare their observations for consistency with the service and maintenance records. Verify the chassis Vehicle
entification Number (VIN) number from the vehicle identifi-
Id
cation plate, as well as the mileage and hours on the vehicle.
Make a Preliminary Investigation
These steps consist of external inspections and
that will be valuable when combined with the results of the
parts examination.
1. Look for leaks, cracks or other damage that can
point to the
2. Make note of obvious lea
A missing fill or drain plug would be an obvious
cause for concern.
3. Look for cracks in the carrier housing (harder to see,
but s
4. Does the general mechanical condition of the vehicle
ind
icate proper maintenance or are there signs of
neglect?
5. Are the tires in good condition and do
match?
6. If equipped with a torque-limiting device, is it working properly?
cause of the failure.
ometimes visible).
occurred before?
prior to the failure?
observations
ks around plugs and seals.
the sizes
Document the Problem
Here are some guidelines for starting to learn
including questions to ask:
1. Talk to the operator of the truck.
2. Look at the service records.
3. Find out when the truck was last serviced.
4
about a failure,
During the preliminary investigation, w
of the ordinary for later reference. Items that appear insignificant now may take on more importance when the subassemblies are torn down.
rite down anything out
Prepare the Parts for Inspection
Inspection
After the preliminary investigation, locate the failure and prepare the part for examination. In carrier
be necessary to disassemble the unit.
1. When disassembling subassemblies and parts, do
not clean the parts
destroy some of the evidence.
2. When tearing down the drive axle, do it
mended manner. Minimize any further damage to the
.
unit
3. Ask more questions when examining the interior
the carrier . Does the lubricant meet the manufacturer
specifications regarding quality, quantity and viscosity? As soon as you have located the failed part, take
to analyze the data.
time
immediately since cleaning may
failure analysis, it may
in the recom-
Find the Cause of the Failure
Here begins the real challenge to determine the exact cause of
the failure. Keep in mind that there is no benefit to replacing a
failed part without determining the cause of the failure. For
example, after examining a failed part and finding that the failure is caused by a lack of lubricati
there was an external leak. Obviously, if there is an external
leak, just replacing the failed gear is not going to correct the
situation.
of
Another important consideration is
type of failure which can be a valuable indicator for the cause
of failure. The following pages show different types of failures
and possible causes. Use this as a guide in determining types
of failures and in correcting problems.
on, you must determine if
to determine the specific
Correct the Cause of the Problem
Once the cause of the problem has been determined, refer to
the appropriate service manual to perform the repairs.
Inspection
5
Inspection
Inspection
Clean
1. Wash steel parts with ground or polished surfaces in
solvent. There
vents available. Kerosene and diesel fuel are acceptable.
Gasoline is not an acceptable solvent because of its
eme combustibility. It is unsafe in the workshop envi-
extr
ronment.
2. Wash castings or other rough parts in solvent or
clean in hot solution tanks
tions.
Note: If a
hot solution tank is used, make sure parts are
heated thoroughly before rinsing.
3. Rinse thoroughly to remove all traces of the cleaning
ion.
solut
4. Dry parts immediately with clean rags.
5. Oil parts.
• If parts are to be reused immediately: Lightly oil.
• If parts are to be stored: Coat
sion resistant paper and store in a clean, dry place.
are many suitable commercial sol-
WARNING
using mild alkali solu-
with oil, wrap in corro-
Inspect Axle Housing
Axle housing inspection and repairs are limited to the following checks or repairs.
• Visually inspect axle housing for cracks, nicks and
burrs
on machined surfaces.
• Check carrier bolt holes and studs for foreign material.
• Replace damaged fasteners. Look
cross-threaded holes
CAUTION
Any damage which affects the alignment or structural integrity of the housing requires housing replacement. Do not
pair by bending or straightening. This process can affect
re
the material’s properties and cause it to fail completely
under load.
• Check all seals and gaskets.
Note: Replace
ket compound (included in many repair kits). The compound provides a more effective seal against lube
seepage and
when replacing parts.
conventional gaskets with silicone rubber gas-
is easier to remove from mating surfaces
for loose bolts or
1
2
1 - Axle housing
2 - Machined surface
6
Inspect Components
Inspect all steel parts for:
• Notches, visible steps or grooves created by wear.
• Pitting or cracking along gear contact lines.
• Scuffing, deformation or discolorations. These are
signs of
related to low lubrication levels or improper lubrication practices.
In addition, inspect the following for damage:
• Differential gearing
• Bearings for loose fit on drive pinion, and differential
bearin
• All fasteners for rounded heads, bends, cracks or
dam
excessive heat in the axle and are usually
gs.
aged threads.
Inspection
• Inspect machined surfaces of cast or malleable
parts. They
scoring, and wear .
• Look for elongation of drilled holes, wear on surfaces machined for bearing fits and nicks or burrs in
mating sur
must be free of nicks, burrs, cracks,
faces.
Inspect Primary Gearing
Before reusing a primary gear set, inspect teeth for signs of
excessive wear. Check tooth contact pattern for evidence of
incorrect adjustment.
Inspection
7
Differential Carrier Assembly
Differential Carrier Assembly
1 - Carrier fastener
2 - Carrier assembly
1
2
8
S110 Carrier Assembly
Carrier Assembly
30
29
28
27
21
25
24
26
20
17
19
22
16
18
31
23
12
13
10D
11
10C
10B
10, 10A
(10A includes items 10B, 10C and 10D)
9
8
7
6
5
4
15
14
3
Carrier Assembly
32
(Optional Truetrac)
2
1
9
Carrier Assembly
1 - Pinion Nut
2 - End Yoke
3 - Slinger
4 - Outer Pinion Bearing Cone
5 - Outer Pinion Bearing Cup
6 - Pinion Spacer
7 - Inner Pinion Bearing Cup
8 - Inner Pinion Bearing Cone
9 - Drive Pinion
10 - Carrier Housing
10A - Carrier Housing Assembly
10B - Switch
10C - Capscrew
10D - Backing Ring
11 - Ring Gear
12 - Ring Gear Bolt
13 - Ring Gear Bearing Cone
14 - Ring Gear Bearing Cup
15 - Ring Gear Bearing Adjuster
16 - Side Pinion Thrust Washer
17 - Side Pinion
18 - Side Gear
19 - Differential Shaft
20 - Pin
21 - Capscrew
22 - Flat Washer
23 - Flanged Half Cap
24 - Plain Half Cap
25 - Cotter Pin
26 - Side Gear Thrust Washer
27 - Differential Case
28 - Differential Case Bearing Cone
29 - Differential Bearing Cup
30 - Differential Case Bearing Adjuster
31 - Pipe Plug
32 - Optional Truetrac
10
S130 Carrier Assembly
Carrier Assembly
31
30
29
28
19
20B
27
20A
22
17
26
25
18
21
23
32
24
9
15
14
10D (Optional)
11
12
10B (Optional)
10C (Optional)
10, 10A (Optional)
(10A includes items 10B, 10C and 10D)
8
7
6
5
4
3
13
16
Carrier Assembly
1 - Pinion Nut
2 - End Yoke
3 - Slinger
4 - Outer Pinion Bearing Cone
5 - Outer Pinion Bearing Cup
6 - Pinion Spacer
7 - Inner Pinion Bearing Cup
8 - Inner Pinion Bearing Cone
9 - Drive Pinion
10 - Carrier Housing
10A - Carrier Housing Assembly
10B - Switch
10C - Capscrew
10D - Backing Ring
11 - Diff Case Dowels
12 - Ring Gear
13 - Ring Gear Bolt
14 - Flange Half Bearing Cone
15 - Flange Half Bearing Cup
2
1
16 - Fland Half Bearing Adjuster
17 - Side Pinion Thrust Washer
18 - Side Pinion
19 - Side Gear
20A - Differential Shaft
20B - Differential Stub Shaft
21 - Pin
22 - Capscrew
23 - Flat Washer
24 - Flange Half Cap
25 - Plain Half Cap
26 - Cotter Pin
27 - Side Gear Thrust Washer
28 - Plain Half Diff Case
29 - Plain Half Bearing Cone
30 - Plain Half Bearing Cup
31 - Plain Half Bearing Adjuster
32 - Pipe Plug
33 - Optional Truetrac
11
Differential Carrier Assembly
Remove Differential Carrier
Standard Differentials
1. Block the vehicle.
2. Drain axle lubricant. Remove bottom two (2) capscrews.
3. Disconnect driveline.
4. Remove axle shafts. (If used, remove lock washers
and tap
er dowels.)
WARNING
WARNING
Do not lie under carrier after fasteners are removed. Use
ission jack to support differential carrier assembly
transm
prior to loosening fasteners.
CAUTION
CAUTION
Do not strike the shaft head with a steel hammer. Do not
sels or wedges to loosen shaft or dowels.
use chi
5. Remove carrier capscrews and washers.
6. Remove differential carrier assembly.
12
Differential Carrier Assembly
y
Install Differential Carrier
IMPORTANTIMPORTANT
Before installing carrier assembly, inspect and thoroughly
clean interior of axle housing using an appropriate solvent
and clean rag.
1. Apply Spicer approved RTV compound on axle
housing mating surface as shown in the illustration.
Completely remove all old gasket material prior to
applying new material. Compound will set in 20 minutes. Install carrier before compound sets or reapply.
1
1 - Apply RTV gasket in this pattern
TIP: To assist in installing complete differential carrier use
two pieces of threaded rod (M14 X 2) threaded into carrier
capscrew holes. Rod should be approximately 4" (102 mm)
long. Use these to pilot the carrier into the housing.
2. Install carrier to housing, lock washers and capscrews. Torque to proper specification. Torque to
142–158 lbs. ft. (193–214 N•m).
3. Install axle shafts and axle stud nuts.
Add axle lubricant. Fill to bottom of filler hole in car-
4.
.
rier
5. Connect main driveline and lubricate joints.
Differential Carrier
Assembl
13
Remove Wheel Differential
Differential Carrier Assembly
Note: Omit this step if the gear set is to be replaced. If gear
set is to be reused, check tooth contact pattern and ring
gear backlash before disassembling differential carrier.
When checking backlash, a yoke must be installed and
torqued to get an accurate reading. Best results are
obtained when established wear patterns are maintained
in used gearing.
1. Mount differential carrier in repair stand.
Note: For easier disassembly
ion (self-locking) nut.
, loosen but do not remove pin-
3. Remove capscrews and bearing ca
ing adjusters and remove adjusters and
cups.
4. Lift ring gear and differential
assembly out of carrier.
ps. Back off bear-
bearing
2. Punch mark bearing caps. If reusing
punch mark bearing adjusters for reference during
assembly.
1
1 - Punch Marks
gear set, also
14
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